Stud Welding & Fasteners, Inc.

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May 24, 2015 By mcampbell

What Is CD (Capacitor Discharge) Stud Welding?

Stud welding is a technique similar to flash welding where a fastener or specially formed nut is welded onto another metal part, typically a base metal or substrate. The fastener can take different forms, but typically fall under threaded, unthreaded or tapped. The bolts may be automatically fed into the spot welder. Weld nuts generally have a flange with small nubs that melt to form the weld. Weld studs are used in stud welding systems.

CD Stud WeldingCapacitor Discharge stud welding eliminates drilling, tapping, punching, riveting, gluing, and screwing; and is especially beneficial when working with thin gauge materials due to the absence of reverse-side marring or discoloration. This process is suitable for studs ranging in size from #4-40 (M3) thru 3/8-16 (M10). During the CD process, the capacitors are charged to a setting pre determined on the front of the power supply. The CD gun is loaded with a weld stud and pushed into the base material under spring pressure. The tip touches the workpiece which closes the electrical circuit. Upon trigger from the CD gun the capacitors are emptied, the stud and workpiece surface from a molten material and solidfy together forming a solid weld. The welding time for CD studs is approx 3 milliseconds.

It started in the 1940’s when a welder had to attach threaded fasteners onto ships in a naval shipyard. He did this by holding a stud flush against the base metal and welding a fillet around the base of the stud. This was a very slow process so he came up with the idea of holding the stud in an electrode holder and touching the end of the stud to the spot where it was to be welded on the base metal and quickly lifting the stud from the base plate drawing an arc and after a short welding time he pushed the stud down into the molten puddle that had formed during the arcing. This resulted in the extinguishing of the arc which in turn resulted in a contiguous weld between the base plate and the stud. This man realized that in order to obtain consistent results he would have to design a way to lift the stud a constant amount in order to have a constant arc length and a constant weld time. He came up with the idea of holding the stud in a chuck and using a solenoid to lift the stud away from the base plate which would create an arc and having a timer that would de-energize the solenoid after a predetermined amount of time. With the use of these modifications it was possible to achieve welding consistency.

Over the years welding stud manufacturers have made improvements to the stud welding process. On of which was the use of a solid aluminum flux ball attached to the weld base of the stud instead of the granular flux that bad been originally used. This was such an improvement over the granular flux, most stud manufacturers changed to the use of a solid flux over time.

Several standard handgun models are available from stock to accommodate routine applications, while automated production systems are available on a custom-designed basis for high volume applications.

Stud Welding & Fasteners, Inc. supplies CD stud welding equipment for a range of markets all over the United States, including the automotive, construction, and industrial, as well as original equipment manufacturers and building contractors. SWF offers externally threaded fasteners, shear connectors, concrete anchors, punching resistor studs, inserts, ports, pipe and cable hangers, weld studs and bosses, and the equipment used to apply, assemble, and weld stud fasteners. Give us a call at (800) 936-1948 for more information.

Filed Under: CD Stud Welding Tagged With: Capacitor Discharge Stud Welding, CD Stud Welding Equipment

February 13, 2015 By mcampbell

CD Stud Welding – How It Works and How It Doesn’t Work.

Stud Welding is a simple process, but it’s also simple to make it not work which can frustrate your operators.

Here we’ll discuss the process of CD Stud Welding and what to look for if you’re having trouble.

CD = Capacitor Discharge = Stored and Released Energy

Capacitor Discharge Stud Welding, OklahomaIt’s hard to fix something if you don’t know how it works, so let’s talk about the process of CD Stud Welding.

CD means Capacitor Discharge. Energy/Voltage is stored in the Capacitors and Discharged when the guns trigger is pulled. This all happens in a millisecond.

CD studs will have an ignition tip at the weld base. This provides the proper gap, much like a spark plug needs the correct gap to attain a sufficient arc. The ignition tip will be eliminated during the weld process, and the spring pressure will take over and force the stud into the weld. Be sure you are using a high quality CD stud to ensure a repeatable weld! (Like the CD Studs we sell!)

Set Up is King

Proper setup of your equipment will make or break you.

Like we said, it’s easy to make CD Stud Welding not work, but just as easy to get it right!

Ground Connection – A loose, indirect, or improper ground will inhibit the weld from being focused at the weld base. Remember, the weld is going to happen in a millisecond. If any of that energy is lost somewhere else, your weld will be weak. We highly recommend grounding directly to your work piece, and a double ground is essential for aluminum.

Stick out – Set your gun up so that 1/8″ of the stud is protruding past your footpiece or tripod legs. Basically, the more stick out, the more you are compressing the spring. Then set your spring pressure if equipped.

Spring Pressure – Most newer CD Guns allow the spring pressure to be adjusted. Tightening the spring pre-loads the spring which will force the stud into the weld pool harder and faster. Set the correct spring pressure according to the diameter of stud you are shooting. The larger the diameter, the more spring pressure you want. Aluminum will also require more spring pressure relative to the same diameter stud in steel. Aluminum cools faster, so you want to get the stud into the molten pool faster.

Setting your voltage – Check your stud welder’s manual for the correct settings, but for most CD Stud Welders you have one adjustment on your power supply. Adjust the voltage according to the diameter of stud you are shooting. Larger diameter = more voltage. Aluminum also requires a higher voltage setting than a similar diameter in steel.

Surface Preparation – Because the CD Welding Process happens so quickly, the surface you are welding to is very important. The surface area should be clean and free of abrasions.

  • Waterjets and other cutting machines can leave an oily residue. Clean the surface with Acetone if necessary.
  • If you have to remove paint from your weld surface, use a very high grit sandpaper. You shouldn’t be able to feel grooves or scratches with your finger.
  • Location Marking – using a center punch to mark your location for the stud is inadvisable. Remember, the ignition tip on the CD Stud sets the proper gap for the arc process. When you put the ignition tip in the punch mark, you are reducing the distance of the stud to the surface and therefore will compromise the integrity of the arc and weld. Instead, use a template. We can set you up with a template tube adapter for the front of your gun that will eliminate the need for a center punch.

Service – Knowing how to use your stud welding equipment will improve your shops efficiency and your end product. Just call (800-936-1948) if you are having trouble with your equipment or your application. We’re here to help! One of our experienced service techs will be glad to help you!

Filed Under: CD Stud Welding Tagged With: Capacitor Discharge Stud Welding, CD studs, oklahoma stud welding products, stud welder oklahoma city, stud welding, stud welding equipment, welding best practices, welding service

January 9, 2015 By mcampbell Leave a Comment

Drawn Arc Stud Welding Best Practices

Drawn Arc Stud Welding is generally used to weld large diameter fasteners to rougher and thicker base metals. Mild steel, stainless steel, and aluminum are applicable materials for arc stud welding

The Arc process is commonly used in most fabricating/structural steel shops. Arc stud welding allows almost any size or type of weld stud to be welded. Studs must be manufactured from weldable material and designed with a special arc stud tip. With the Arc process, you obtain a full fusion weld that becomes stronger than the stud itself.

Be sure you are using a high quality ARC stud to ensure a repeatable weld! (Like the Studs we sell!)

Crucial Setting

Proper setup of your equipment will make or break you. There are many different types of Arc studs so there are many different accessories, ferrules, and settings. We can help. In this news letter we are specifically referring to headed studs.

Ground Connection

A loose, indirect, or improper ground will inhibit the weld from being focused at the weld base. Make sure that the ground surface is bare metal. Grind off any paint for Thru deck application. For shop applications, ground to your work piece or ground to the metal table your work piece is on.

Leg, Foot Piece, & Ferrule Grip Set Up

  • Shop Application
    will consists of two legs, a ferrule grip, and phenolic foot piece. These will need to be set up so the stud is center of the ferrule.
  • Thru Deck Application
    will consists of two legs, a ferrule grip, and weld thru deck foot assembly. Align all accessories so the stud is center of the ferrule. Thru deck accessories may take more time to get a straight alignment since there are 3 pieces.

Lift

On a Tru-Weld HD Gun, the lift is adjusted in the back of the gun. Take the screw out of the back of the cap and remove cap. Then take the set screw(s) out from the side of the lift adjustment insert. Turn the lift adjustment screw counter clockwise to get more lift. Clockwise to get less lift. Once desired lift is attained, place the side screw(s) back in place; DO NOT OVER TIGHTEN! It will crush the threads on the lift adjustment screw and make it very difficult to adjust the lift!

Dampener

Tru-Weld guns are equipped with a dampener. These can be adjusted in and out so the stud plunge releases down quickly or slowly.

Setting Your Voltage and Time

Settings for each size stud are on all Tru-Weld equipment. The thickness of the material you are welding to must be at least 1/3 of the stud diameter. When shooting Thru-Deck the time will be adjusted to burn thru the decking.

Surface Preparation

The weld area needs to be clean and free of foreign debris. Welding through galvanization is not recommended, nor will you get a repeatable result. You should not weld when surface is wet, dirty, rusty, or especially painted.

Drawn Arc Stud Welding
Here is what the bottom of a stud will look like, once knocked off, when the metals surface is painted.

This will slow down a any crew tremendously! It will also increase your scrap factor.

Service

Just call if you are having trouble with your stud welding equipment or your application. We’re here to help! One of our experienced service tech’s will be glad to help you!

Stud Welding and Fasteners, Inc.
(800) 936-1948

Filed Under: Arc Stud Welding Tagged With: drawn arc stud welding, equipment for stud welding, high quality studs, knoxville stud welding, memphis stud welding, stud welding techniques

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Stud Welding and Fasteners, Inc.
1032 Tennessee Blvd.
Lebanon, TN 37087
(800) 936-1948

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Stud Welding and Fasteners, Inc.
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1032 Tennessee Blvd.
Lebanon, TN 37087
Phone: (800) 936-1948

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